RFID (Radio Frequency Identification) technology has become a major focus of global attention. The core components of an RFID system include RFID tags, readers, and antennas. Among these, the antenna plays a crucial role by transmitting or receiving radio frequency signals in the form of electromagnetic waves. In RFID systems, there are two main types of antennas: tag antennas and reader antennas. The primary function of a tag antenna is to efficiently transfer energy into and out of the tag’s chip. When sending data, it converts high-frequency current into electromagnetic waves, and when receiving, it transforms those waves back into current.
RFID antennas can be manufactured using various techniques. This article explores and analyzes the production technologies of RFID antennas, with a special focus on the latest methods, including printed RFID antennas and related innovations, while also looking ahead to their future potential.
Three main manufacturing techniques for RFID antennas are widely used: etching, coil winding, and printing. Among these, conductive ink-based printed antennas have emerged as a promising new approach in recent years.
Each of these antenna types is tailored for RFID tags operating at different frequencies. Low-frequency RFID tags typically use wound antennas, while high-frequency tags often employ etched antennas made from materials like aluminum or copper. UHF RFID tags, on the other hand, mostly rely on printed antennas.
The etching method, also known as a subtractive fabrication technique, involves several steps. First, a copper foil is laminated onto a plastic film. A photosensitive layer is then applied, dried, and exposed to a positive image of the desired pattern. After development, the exposed areas are removed, and the remaining copper is etched away to create the final antenna shape.
Etched antennas offer high precision and excellent RF performance, making them ideal for matching the reader's interrogation signal. However, their main disadvantage is the high cost involved in the manufacturing process.
In contrast, the coil winding method involves wrapping the antenna coil around a tool and securing it in place. This method is commonly used for low-frequency RFID tags (125–134 kHz), but it is associated with higher costs and slower production speeds.
Printed antennas, on the other hand, are created by directly printing conductive ink onto an insulating substrate, such as a film, to form the antenna and circuit. This method is considered an additive manufacturing technique and includes various printing processes like screen printing, offset printing, flexography, and gravure printing. Screen and gravure printing are currently the most mature techniques.
Compared to etched and wound antennas, printed antennas offer several unique advantages:
First, they allow for precise adjustment of electrical parameters to optimize the performance of the RFID tag. Key parameters such as resonant frequency, Q value, and impedance can be fine-tuned by modifying line width, layer thickness, and other factors.
Second, printed antennas can be shaped in any form to suit specific design requirements. Whether it's curved surfaces, angled shapes, or complex geometries, they can be easily adapted without compromising performance.
Third, they are compatible with a wide range of base materials, including PVC, PET-G, PET, ABS, PC, and even paper-based substrates. This flexibility makes them suitable for diverse applications, especially where traditional winding methods fall short.
Fourth, printed antennas are highly adaptable to different wafer modules from various manufacturers. As RFID becomes more widespread, the diversity of IC chips increases, and the flexibility of printed antennas allows them to match different chip formats for optimal performance.
Overall, the advancement of printing technology has significantly reduced the cost of RFID tags, making them more accessible and practical for a wide range of industries and applications.
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